Method of constructing an insulated shallow pier foundation building

ABSTRACT

A method of constructing a shallow pier foundation building that includes a) placing a plurality of insulating pier forms along a perimeter of the building; b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form; c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.

REFERENCE TO RELATED APPLICATION

The present nonprovisional patent application is entitled to and claims the right of priority under 35 U.S.C. §119(e) of U.S. Provisional Patent Application Ser. Nos. 61/027,532, filed Feb. 11, 2008 and 61/074,173, filed Jun. 20, 2008, which are hereby incorporated herein in its entirety by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to systems, methods and articles for constructing a shallow pier foundation building and in particular, to such systems and methods that utilize wall forming systems and/or insulating concrete walls to construct structures.

2. Description of the Prior Art

In home and building construction, exterior grade beams, or footings, are often utilized which are formed in ditches, or the like, to support the exterior walls of the building. These concrete grade beams are often poured in conjunction with a continuous slab, which extends in the area between the grade beams and can be poured simultaneously with, or separate from, the grade beams.

However, problems are encountered in connection with these types of arrangements, especially when the building site contains soil of varying compactness and plasticity. For example, in cases when a building site is extensively graded to level it and soil is moved from one portion of the lot to the other, the soil immediately underneath the removed soil is relatively compact while the soil that is moved to other portions of the building site is relatively loose. This, of course, causes differential movements of the foundation and the grade beams and potential problems with regard to cracking, breaking, or the like.

In northern latitudes, such as, for example, in Canada, northern Europe and the northern portions of the United States, soils, and particularly fine grained water saturated soils, are susceptible to the formation of ice lenses and frost heave. These phenomena can greatly diminish the stability and integrity of structures embedded in such soils. In many cases, footings are placed at a depth of not less than the depth of normal frost penetration. This prevents damage to the footing from the swelling and shrinkage of the surrounding soil caused by freeze-thaw cycles or displacement from frost heaving. However, while placing the footing below the depth of frost penetration may protect the footing from the effects of frost action, the pier that transfers the loads from the supported structure to the footing remains above the frost line and therefore remains vulnerable to frost and ice action.

The mechanisms of frost heave and frost action are well known to persons skilled in the art. The main phenomenon of concern to the construction industry is the displacement, laterally and vertically, of foundation members due to loads placed upon them from frost action. Where surrounding soil is frozen to a pier connecting a supported structure to a supporting footing, movement of the soil frozen to the pier will displace the pier. This will diminish the stability of the footing and structure to which it is attached no matter the depth of the footing below the frost line. In northern climates, a pier must be of a significant length to connect a footing placed below the frost line to the structure on the surface. Most of the entire length of the pier embedded in frost susceptible soil will be vulnerable to frost action.

Several techniques have been suggested to combat these problems. For example, a concrete pier system has been suggested in which relatively deep holes are formed and concrete poured into the holes to form a pier for the exterior grade beam. However, these concrete piers have several disadvantages. For example, the depth to which the beam is formed is often based on a single soil test at one area, which is not necessarily representative of the entire area. Thus the pier, although adequate in height for the particular area tested, may be insufficient to adequately support the foundation in other areas having a softer or more plastic soil composition.

Also, the drills used to drill the pier holes do not necessarily clean out the bottom of the holes which causes difficulty in the stability of the beam once it has been poured. Further, the pier drill may encounter soft rock strata or the like which jams the drill and causes undue delays. Still further, upheaval forces, i.e., forces in the upward direction often occur due to the changes in the wetness or the dryness of the soil, which causes a poured concrete pier to fail. Still further, in soils having a large percentage of clay there is a certain practical limit on the height of the pier, which does not necessarily support the foundation adequately in this type of environment.

Other techniques for constructing an adequate exterior grade beam support include a post tension technique in which cables are passed through the forms for the grade beams and, after the concrete is poured thereover, are placed in very high tensile stress to increase the resistance of the foundation to cracking or failing. However, these types of techniques require a great deal of labor and are also subject to fail.

As indicated above, the above-described problems can be exacerbated when freeze thaw cycles are introduced. If the piers are not placed and spaced properly with adequate depth, upward forces that can cause heaving are generated during freezing conditions followed by downward forces during thawing conditions. The resulting heaving and relaxation can lead to cracks and eventual failure of a slab and pier foundation system.

U.S. Pat. No. 4,125,975 discloses a foundation on grade support for manufactured housing that attempts to minimize vertical or lateral shifting of the home, due to earth movements resulting from mud or freeze-thaw induced shifting of the supporting soil. The foundation arrangement includes a plurality of telescoping stanchions which are adapted to be raised in order to be connected to the underframe and lowered to a final position.

U.S. Pat. No. 4,754,588 discloses a foundation piling system in which pilings are used to support a foundation system in soil having a varied composition and moisture content. The pilings extend into concrete grade beams forming a portion of a monolithic system including a concrete slab. Flanges extend from the end portions of the pilings that are disposed in the grade beam and a plurality of horizontally extending reinforcing bars extend through openings in the flanges.

U.S. Pat. No. 6,318,700 discloses a mold for a conical concrete pier for use in constructing buildings in frost-prone northern climates.

U.S. Patent Application Publication 2006/0257210 discloses a residential flooring system for use with expansive soil. The system includes a plurality of pre-cast slabs of hardened concrete with structural members such as rebar and/or wire mesh. The system also includes structural drilled pier members that contact the expansive soil and extend upward away from the expansive soil. The pier members have an upper contact surface that extends above the soil. Weight bearing members are attached to the structural members and include a bearing surface that is larger (e.g., has a greater area) than the upper contact surface of the pier or other structural member. The pre-cast slabs are positioned on the weight bearing surfaces so that the slabs are supported by the structural members via the weight bearing members.

U.S. Pat. No. 6,964,139 discloses a column for use in post-frame construction having a two piece construction in which a first or foundation column portion of the column is set into the earth with a proximal end thereof protruding from the earth. The proximal end of the foundation column includes a column bracket for joining the foundation column to a wooden column comprising the second portion of the two piece column. The foundation column of the present invention includes a precast concrete column.

U.S. Patent Application Publication 2008/0016805 discloses panelized building systems that include pre-manufactured floor and stem wall panels that can be built according to site-specific requirements. The floor panels can include height-adjustable members to raise/lower portions of one or more panels to a desired height relative to an underlying surface. The floor panels can be leveled, locked together, and then remaining portions of a building structure can be built around the floor panels in a top-down process. The height-adjustable members can include a pier and jack system that includes a jack screw, a sleeve, and a pier.

The systems described above and those presently known and in use do not provide adequate resistance to frost heave in general or to vertical and lateral movements of the soil, occurring as a result of mud, frost, thawing, etc. in particular. These deficiencies indicate a clear and present need in the art for systems, methods and structures that provide more secure support in an arrangement and/or system for pier and floating slab foundations, which minimize and/or eliminate the deficiencies described above.

SUMMARY OF THE INVENTION

The present invention provides a method of constructing a shallow pier foundation building that includes a) placing a plurality of insulating pier forms along a perimeter of the building; b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form; c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an insulating pier form that can be used according to the invention;

FIG. 2 is a top plan view of an insulating pier form that can be used according to the invention;

FIG. 3 is a perspective view of a partially constructed insulating pier form that can be used according to the invention;

FIG. 4 is a top plan view of a corner connection of an insulating pier form that can be used according to the invention;

FIG. 5 is a perspective view of an insulating concrete form that can be used according to the invention;

FIG. 6 is a perspective view of an insulating concrete form that can be used according to the invention;

FIG. 7 is a top plan view of an insulating concrete form that can be used according to the invention;

FIG. 8 is a front elevation view of a connecting member that can be used with the insulating concrete forms according to the invention;

FIG. 9 is a top plan view of a connecting member that can be used with the insulating concrete forms according to the invention;

FIG. 10 is a front elevation view of a connecting member that can be used with the insulating concrete forms according to the invention;

FIG. 11 is a perspective view of an insulating concrete footer form panel that can be used according to the invention;

FIG. 12 is a perspective view of an insulating concrete footer form panel that can be used according to the invention;

FIG. 13 is a plan view of an arrangement of insulating pier forms and insulating concrete forms according to embodiments of the invention;

FIG. 14 is a cross-section elevation view of a corner concrete pier and floating concrete slab according to embodiments of the invention;

FIG. 15 is a cross-section elevation view of an insulating concrete wall and floating concrete slab according to embodiments of the invention; and

FIG. 16 is a cross section elevation view of a portion of a frost wall according to embodiments of the invention; and

FIG. 17 is a cross section elevation view of a portion of a frost wall according to embodiments of the invention.

DETAILED DESCRIPTION OF THE INVENTION

For the purpose of the description hereinafter, the terms “upper”, “lower”, “inner”, “outer”, “right”, “left”, “vertical”, “horizontal”, “top”, “bottom” and derivatives thereof, shall relate to the invention as oriented in the drawing Figures. However, it is to be understood that the invention may assume alternate variations and step sequences except where expressly specified to the contrary. It is also to be understood that the specific devices and processes, illustrated in the attached drawings and described in the following specification, is an exemplary embodiment of the present invention. Hence, specific dimensions and other physical characteristics related to the embodiment disclosed herein are not to be considered as limiting the invention. In describing the embodiments of the present invention, reference will be made herein to the drawings in which like numerals refer to like features of the invention.

Other than where otherwise indicated, all numbers or expressions referring to quantities, distances, or measurements, etc. used in the specification and claims are to be understood as modified in all instances by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that can vary depending upon the desired properties, which the present invention desires to obtain. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from the standard deviation found in their respective measurement methods.

Also, it should be understood that any numerical range recited herein is intended to include all sub-ranges subsumed therein. For example, a range of “1 to 10” is intended to include all sub-ranges between and including the recited minimum value of 1 and the recited maximum value of 10; that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. Because the disclosed numerical ranges are continuous, they include every value between the minimum and maximum values. Unless expressly indicated otherwise, the various numerical ranges specified in this application are approximations.

As used herein, the term “expandable polymer matrix” refers to a polymeric material in particulate or bead form that is impregnated with a blowing agent such that when the particulates and/or beads are placed in a mold and heat is applied thereto, evaporation of the blowing agent (as described below) effects the formation of a cellular structure and/or an expanding cellular structure in the particulates and/or beads and the outer surfaces of the particulates and/or beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold.

As used herein, the term “polymer” is meant to encompass, without limitation, homopolymers, copolymers and graft copolymers.

As used herein, the terms “(meth)acrylic” and “(meth)acrylate” are meant to include both acrylic and methacrylic acid derivatives, such as the corresponding alkyl esters often referred to as acrylates and (meth)acrylates, which the term “(meth)acrylate” is meant to encompass.

As used herein, the term “floating slab” refers to a structural engineering practice whereby a concrete slab, that is to serve as the bottom floor of a structure, is formed by setting a mold into the ground and pouring concrete into the mold, leaving no space between the ground and the structure.

As used herein, the terms “insulating concrete form” or “ICF” refer to stay-in-place formwork for cast-in-place reinforced-concrete walls. A typical ICF includes interlocking modular units that can be dry-stacked and filled with concrete.

As used herein, the term “reinforced concrete” refers to concrete into which reinforcement bars (“rebar”) or fibers have been cast to carry tensile loads in order to strengthen a structure that would otherwise be brittle.

As used herein, the term “concrete pier” refers to a cast-in-place reinforced-concrete structure typically constructed with a stay-in-place, single-use form having a first end below ground level and a second end protruding at or above ground level.

The present invention is directed to shallow pier foundation structures, pier and floating slab structures, and to methods of constructing such structures.

Embodiments of the invention provide methods of constructing a shallow pier foundation structure or building that includes placing a combination of insulating pier forms and insulating concrete forms along a planned perimeter of the structure or building, placing a concrete composition in the insulating piers and insulating concrete forms, and placing a concrete slab in the space defined by the insulating pier forms and insulating concrete forms.

In an exemplary embodiment of the invention shown in FIGS. 1 and 2, insulating pier form 10 includes footer portion 12 and post portion 14. Post portion 14 includes first panel member 16 having first end 18 and second end 20; second panel member 22 having first end 24 and second end 26, where first end 24 is connected to second end 20 of first panel 16 by way of connector 28; third panel member 30 having first end 32 and second end 34, where first end 32 is connected to second end 26 of second panel 22 by way of connector 36; and fourth panel member 38 having first end 40 and second end 42, where first end 40 is connected to second end 34 of third panel 30 by way of connector 44 and second end 42 is connected to first end 18 of first panel 16 by way of connector 46.

Footer portion 12 includes first panel member 50 having first end 52 and second end 54; second panel member 56 having first end 58 and second end 60, where first end 58 is connected to second end 54 of first panel 50 by way of connector 62; third panel member 64 having first end 66 and a second end 68, where first end 66 is connected to second end 60 of second panel 56 by way of connector 70; and fourth panel member 72 having first end 74 and second end 76, where first end 74 is connected to second end 68 of third panel 64 by way of connector 78 and second end 76 is connected to first end 52 of first panel 50 by way of connector 80.

A bottom surface of panel 22 is attached to first post support 82. First end 84 of post support 82 is attached to a top surface of panel 50 and a second end 86 of post support 82 is attached to a top surface of panel 64. A bottom surface of panel 38 is attached to second post support 88. First end 90 of post support 88 is attached to a top surface of panel 50 and a second end 90 of post support 88 is attached to a top surface of panel 64.

In embodiments of the invention, water impervious fabric 85 is placed over the portion of the outward facing surface of insulating pier form 10. As used herein, “outward facing surface” refers to the portion of the surface of a form that will be exposed to the earth and weather outside of the planned building. Typically, top edge 87 of water impervious fabric 85 will extend above grade when the building is completed.

Typically, water impervious fabric 85 is a layered fabric that includes channels, capillaries, and/or dimples that provide for seepage and/or drainage of moisture. The materials of construction for water impervious fabric 85 are typically pressure resistant, rot-proof, and resistant to saline solutions, inorganic acids, alkalis, and liquids such as alcohols, organic acids, esters, ketones, and similar substances and are typically not damaged or affected by minerals, humic acid, or bacterial decomposition in the earth and is resistant to bacteria, fungi and/or microorganism. In many embodiments, water impervious fabric 85 is constructed using thermoplastics, non-limiting examples of which include polyethylene and polypropylene.

In embodiments of the invention, shown in FIGS. 3 and 4, post portion 14 can be constructed by combining connecting panels 94 using connecting braces 95 and connectors 28, 36, 44 and 46. As a non-limiting example, connector 28 includes a first receiving space defined by end plate 96, first flange 97 and common base 98 and a second receiving space defined by end plate 96, second flange 99 and common base 98. In this embodiment, end 24 fits securely into the first receiving space and end 20 fits securely into the second receiving space connecting first panel 16 to second panel 22.

As shown in FIG. 3, a plurality of connecting panels 94 can be used to provide the height, surfaces and form of post portion 14. A top surface of connecting panels 94 includes a plurality of slots 93, which are adapted to receive bottom portion 89 of connectors 95. A similar plurality of slots (not shown) are included along a bottom surface of connecting panels 94 and are adapted to receive top portion 91 of connectors 95.

When used according to the present invention, rebar is typically placed in footer portion 12 and post portion 14 prior to placing concrete into insulating pier form 10. In many cases, the rebar can extend from insulating pier form 10 to other insulating pier forms and/or adjacent insulating concrete forms.

Various insulating concrete forms can be used in the structures and methods of the present invention. As non-limiting examples, the insulating concrete forms disclosed in U.S. Pat. Nos. 5,333,429; 5,390,459; 5,566,518; 5,568,710; 5,657,600; 5,709,060; 5,787,665; 5,822,940; 5,845,449; 5,887,401; 6,098,367; 6,167,624; 6,170,220; 6,235,367; 6,314,697; 6,318,040; 6,336,301; 6,363,683; 6,438,918; 6,526,713; 6,588,168; 6,647,686 and 6,820,384; U.S. Patent Application Publication Nos. 2002/0116889 and 2003/0005659; and copending U.S. Publication Application Nos. 2006/0251851; 2008/0066408; 2008/0104911; 2008/0104912; and 2008/0107852; the relevant portions of which are incorporated herein by reference. Commercially available insulating concrete forms that can be used include, but are not limited to those available under the tradenames GREENBLOCK® available from Greenblock Worldwide Corp, Stuart, Fla.; ECO-Block available from ECO-Block, LLC, Dallas, Tex.; and QUAD-LOCK® available from Quad-Lock Building Systems Ltd., Surrey, BC, Canada.

In particular embodiments of the invention, the insulating concrete forms can be those available under the SAFE Block® trade name from SYNTHEON Inc., Pittsburgh, Pa. A non-limiting example of this embodiment is shown in FIGS: 5-10. In this exemplary embodiment, insulating concrete form assembly 100 includes footer section 102 and wall section 104, all held together by connecting members 106.

Wall section 104 includes first panel member 108 having first outer panel side 110 including a first wall surface area extending generally vertically thereon; first inner panel side 112 positioned oppositely from first outer panel side 110; and at least two first slots 114 in first inner panel side 112 adapted to accept connecting members 106; second panel member 116 includes second outer panel side 118 including a second wall surface area extending generally vertically thereon and facing oppositely from first panel member 108, second inner panel side 120 positioned oppositely from second outer panel side 118 and facing first inner panel side 112 of first panel member 108; and at least two second slots 122 in second inner panel side 120 adapted to accept connecting member 106. At least two connecting members 106 detachable and securable with respect to first panel member 108 and second panel member 116 adapted to maintain a spatial distance therebetween for defining molding chamber 124 therebetween.

In embodiments of the invention shown in FIG. 8, connecting members 106 include first flange 126 adapted to be detachably and securably extending within first slot 114 of first panel member 108; a second flange 128 adapted to be detachably and securably extending within second slot 122 of second panel member 116; and mid-section portion 130 adapted to span the distance between first inner panel side 112 and second inner panel side 120. Connecting member 106 can optionally include one or more rebar holders 132 adapted to secure a portion of a reinforcing bar against inner surface 134.

In other embodiments of the invention shown in FIGS. 9 and 10, connecting members 106 can include first flange 126 adapted to be detachably and securably extending within first slot 114 of first panel member 108; second flange 128 adapted to be detachably and securably extending within second slot 122 of second panel member 116; and mid-section portion 130 adapted to span the distance between first inner panel side 112 and second inner panel side 120. Connecting member 106 can optionally include one or more raised portions 129 adapted to hold a portion of a reinforcing bar in place and in contact with a surface of mid-section portion 130.

A variety of connecting members are known in the art and the panels used in the present exemplary embodiment can be adapted to use them. Non-limiting examples of such connecting members are disclosed in U.S. Pat. Nos. 7,032,357; 6,378,260; 5,809,728; 5,890,337; 5,701,710; 4,889,310; and 4,884,382; the relevant portions of which are incorporated herein by reference.

In embodiments of the invention, connecting members 106 and connectors 28, 36, 44 and 46 can be made of plastics, metal, construction grade plastics, composite materials, ceramics, and the like.

Suitable plastics include homopolymers and copolymers of styrene, homopolymers and copolymers of C₂ to C₂₀ olefins, C₄ to C₂₀ dienes, polyesters, polyamides, homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters, polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides, polyurethanes, and combinations thereof.

Suitable construction grade plastics include, but are not limited to reinforced thermoplastics, thermoset resins, and reinforced thermoset resins. Suitable thermoplastics include polymers and polymer foams made up of materials that can be repeatedly softened by heating and hardened again on cooling. Suitable thermoplastic polymers include, but are not limited to homopolymers and copolymers of styrene, homopolymers and copolymers of C₂ to C₂₀ olefins, C₄ to C₂₀ dienes, polyesters, polyamides, homopolymers and copolymers of C₂ to C₂₀ (meth)acrylate esters, polyetherimides, polycarbonates, polyphenylethers, polyvinylchlorides, polyurethanes, and combinations thereof.

Suitable thermoset resins are resins that when heated to their cure point, undergo a chemical cross-linking reaction causing them to solidify and hold their shape rigidly, even at elevated temperatures. Suitable thermoset resins include, but are not limited to alkyd resins, epoxy resins, diallyl phthalate resins, melamine resins, phenolic resins, polyester resins, urethane resins, and urea, which can be crosslinked by reaction, as non-limiting examples, with diols, triols, polyols, and/or formaldehyde.

Reinforcing materials and/or fillers that can be incorporated into the thermoplastics and/or thermoset resins include, but are not limited to carbon fibers, aramid fibers, glass fibers, metal fibers, woven fabric or structures of the mentioned fibers, fiberglass, carbon black, graphite, clays, calcium carbonate, titanium dioxide, woven fabric or structures of the above-referenced fibers, and combinations thereof.

A non-limiting example of construction grade plastics are thermosetting polyester or vinyl ester resin systems reinforced with fiberglass that meet the requirements of required test methods known in the art, non-limiting examples being ASTM D790, ASTM D695, ASTM D3039 and ASTM D638.

The thermoplastics and thermoset resins can optionally include other additives, as a non-limiting example ultraviolet (UV) stabilizers, heat stabilizers, flame retardants, structural enhancements, biocides, and combinations thereof.

Suitable metals include, but are not limited to, aluminum, steel, stainless steel, tungsten, molybdenum, iron and alloys and combinations of such metals. In a particular embodiment of the invention, the metal bars, studs, joists and/or members are made of a light gauge metal.

First panel 108 can include a first slot 136 spanning the vertical length of a first end of panel 108 and a first raised tongue 138 spanning the vertical length of a second end of panel 108. Second panel 116 can include a second slot 140 spanning the vertical length of a first end of panel 116 and a second raised tongue 142 spanning the vertical length of a second end of panel 116.

Adjacent wall sections 104 are adapted to be joined together by, for example inserting tongue 138 into slot 136 of an adjacent wall section 104 and inserting tongue 142 of adjacent wall section 104 into slot 140.

First panel 108 can include a first raised portion 144 spanning the horizontal length of a top surface of panel 108 and a first groove section 146 spanning the horizontal length of a bottom surface of panel 108. Second panel 116 can include a second raised portion 148 spanning the horizontal length of a top surface of panel 116 and a second groove section 150 spanning the horizontal length of a bottom surface of panel 116.

Top and bottom wall sections 104 are adapted to be joined together by, for example inserting raised portion 144 of bottom wall section 104 into groove 146 of top wall section 104 and raised portion 148 of bottom wall section 104 into groove 150 of top wall section 104. Lower portion 127 of connecting member 106 extends into slots in bottom wall section 104 and upper portion 131 extends into slots in top wall section 104 to hold the two sections firmly together.

Footer section 102 includes first footer panel 160, second footer panel 162 and two or more connecting members 106. First footer panel 160 includes upper leg 164, mid leg section 166, lower leg 168, first footer outer side 170, first inner footer side 172 positioned oppositely from outer side 170, and at least two first footer slots 174 adapted to accept connecting member 106. Second footer panel 162 includes upper leg 176, mid leg section 178, lower leg 180, second footer outer side 182, second inner footer side 184 positioned oppositely from outer side 182, and at least two second footer slots 186 adapted to accept connecting member 106.

Connecting members 106 are adapted to be detachably and securably extending within first slot 174 of first footer panel 160 and within second slot 186 of second footer panel 162. Mid-section portion 130 is adapted to span the distance between first inner side 172 and second inner side 184. At least two connecting members 106 detachable and securable with respect to first footer panel 160 and second footer panel 162 adapted to maintain a spatial distance therebetween for defining molding chamber 183 therebetween.

First panel 160 can include a first groove portion 190 spanning the horizontal length of a top surface of panel 160 and a second groove portion 192 spanning the horizontal length of a bottom surface of panel 160. Second panel 162 can include a first groove portion 194 spanning the horizontal length of a top surface of panel 162 and a second groove portion 196 spanning the horizontal length of a bottom surface of panel 162.

First panel 108 can include a first slot 136 spanning the vertical length of a first end of panel 108 and a first raised tongue 138 spanning the vertical length of a second end of panel 108. Second panel 116 can include a second slot 140 spanning the vertical length of a first end of panel 116 and a second raised tongue 142 spanning the vertical length of a second end of panel 116.

Wall section 104 is adapted to be placed on top of footer section 102, for example inserting first raised tongue 138 of wall section 104 into first groove portion 190 of footer section 102 and second raised tongue 142 of wall section 104 into first groove portion 194 of footer section 102. Lower portion 127 of connecting member 106 extends into slots 174 in footer section 102 and upper portion 131 extends into slots in wall section 104 to hold footer section 102 and wall section 104 firmly together as shown, for example, in FIG. 6.

Adjacent footer sections 102 are adapted to be joined together by, for example inserting first tongue 198 extending from a first edge of footer section 102 into first slot 200 of a second edge of an adjacent footer section 102 and inserting second tongue 202 of adjacent footer section 102 into second slot 204.

When used according to the present invention, rebar 181 is typically placed in footer sections 102 and wall section 104 prior to placing concrete into insulating concrete form assembly 100. In many cases, the rebar can extend from insulating concrete form assembly 100 to adjacent insulating concrete form assemblies 100 and/or adjacent insulating pier forms 10.

In embodiments of the invention, at least some of the rebar is held in place using rebar holders 132 or raised portions 129 of connecting members 106.

In embodiments of the invention, water impervious fabric 179 is placed over an outward facing surface of insulating concrete form assembly 100. As shown in FIG. 6, water impervious fabric 179 covers outer surfaces 118 and 178 of insulating concrete form assembly 100.

In an embodiment of the invention, as shown in FIG. 13, insulating concrete form assemblies 100 and insulating pier forms 10 are adapted to fit together and form continuous wall unit 200. In this embodiment, insulating pier forms 10 are placed at the corners of the foundation perimeter and, optionally, spaced along the perimeter and one or more insulating concrete form assemblies 100 bridge the distance between insulating pier forms 10. Further to this embodiment, at least a portion of the outer facing surface of one or more of first panel member 16, second panel member 22, third panel member 30 and fourth panel member 38 of post portion 14; and first panel member 50, second panel member 56, third panel member 64 and fourth panel member 72 of footer portion 12 of insulating pier forms 10 serve to define a concrete mold cavity further defined by molding chamber 124 of wall section 104 and/or molding chamber 183 of footer section 102 of insulating concrete form assemblies 100.

In typical embodiments of the invention, the distance from first panel member 16 to third panel member 30 (“first length”) can be the same or different than the distance from second panel member 22 to fourth panel member 38 (“second length”) of post portion 14 of insulating pier form 10. The first length and/or second length can be at least about 12 inches (0.3 m), in some cases at least about 16 inches (0.4 m) and in other cases at least about 20 inches (0.5 m) and can be up to about 60 inches (1.5 m), in some cases up to about 51 inches (1.3 m) and in other cases up to about 47 inches (1.2 m). The first length and/or second length of the post portion 14 of insulating pier form 10 can independently be any of the values or range between any of the values recited above.

Further to this embodiment, the distance from first panel member 50 to third panel member 54 (“first length”) can be the same or different than the distance from second panel member 56 to fourth panel member 72 (“second length”) of footer portion 12 of insulating pier form 10 is typically greater than the first length and/or second length of the post portion 14 of insulating pier form 10. As such, the first length and/or second length of footer portion 12 can be at least about 14 inches (0.35 m), in some cases at least about 18 inches (0.45 m) and in other cases at least about 22 inches (0.55 m) and can be up to about 63 inches (1.6 m), in some cases up to about 55 inches (1.4 m) and in other cases up to about 51 inches (1.3 m). The first length and/or second length of the footer portion 12 of insulating pier form 10 can independently be any of the values or range between any of the values recited above.

The length of insulating concrete form assemblies 100 can be described in terms of the distance from the first end of panel 108 to the second end of panel 108 and/or the distance from the first edge of footer section 102 to the second edge of footer section 102. As such, insulating concrete form assemblies 100 can have a length of from at least about 2 feet (0.6 m), in some cases at least about 2.5 feet (0.76 m) and in other cases at least about 3 feet (0.91 m) and can be up to about 10 feet (3 m), in some cases up to about 8 feet (2.4 m) and in other cases up to about 6 feet (1.8 m). The length of insulating concrete form assemblies 100 can be any of the values or range between any of the values recited above.

In many embodiments of the invention, the width of footer section 102, as measured from inner footer side 172 of lower leg 168 of first footer panel 160 to inner footer side 184 of lower leg 180 of second footer panel 162 is greater than or equal to the width of wall section 104 as measured from first inner panel side 112 of first panel member 108 to second inner panel side 120 of second panel member 116.

As such, the width of wall section 104 can be at least about 3 in. (7.6 cm), in some cases at least about 4 in. (10.2 cm) and in other cases at least about 5 inches (12.7 cm) and can be up to about 24 inches (61 cm), in some cases up to about 20 inches (51 cm) and in other cases up to about 16 inches (41 cm). The width of wall section 104 can be any of the values or range between any of the values recited above.

The width of footer section 102 can be at least about 4 in. (10.2 cm), in some cases at least about 5 in. (12.7 cm) and in other cases at least about 6 inches (15.2 cm) and can be up to about 36 inches (91 cm), in some cases up to about 30 inches (76 cm) and in other cases up to about 24 inches (61 cm). The width of footer section 102 can be any of the values or range between any of the values recited above.

The height of wall section 104 can be measured as the vertical length of the first end of panel 108. The height of footer section 102 can be measured as the vertical distance from the bottom surface of panel 160 to the base of first raised portion 190 of panel 160. Wall section 104 and footer section 102 can have the same or different heights. As such, the height of wall section 104 and/or footer section 102 can independently be at least about 3 in. (7.6 cm), in some cases at least about 4 in. (10.2 cm) and in other cases at least about 5 inches (12.7 cm) and can be up to about 24 inches (61 cm), in some cases up to about 20 inches (51 cm) and in other cases up to about 16 inches (41 cm). The height of wall section 104 and/or footer section 102 can be any value or range between any of the values recited above.

The vertical height of insulating concrete form assembly 100 is determined by the intended number of courses of wall sections 104 and/or footer section 102 to be used in an overall insulating concrete wall design and corresponds to the sum of those heights.

In embodiments of the invention, prior to using the insulating pier forms and insulating concrete forms according to the invention a trench, ditch or other excavation is dug along the perimeter of an intended building. Typically, the excavation is wider than the width of the insulating pier forms and insulating concrete forms and in many cases at least twice as wide as the insulating pier forms and insulating concrete forms to allow space for placing and otherwise working with the forms, rebar and concrete required for a specific construction project.

After the excavation has been completed, the plurality of insulating pier forms are placed along the proposed building perimeter and the plurality of insulating concrete forms are placed between the insulating piers to form a continuous insulating surface to the surrounding soil. In some embodiments, the insulating pier forms and insulating concrete forms are placed sequentially proceeding around the perimeter of the excavation.

Once the plurality of insulating pier forms and insulating concrete forms are placed, rebar is placed in the forms as required and a concrete composition is placed in the insulating piers and insulating concrete forms and allowed to cure and harden.

Fill can then be placed in the space between the excavation and the outer and inner surfaces of the insulating concrete structure formed with the insulating pier forms, insulating concrete forms, rebar and concrete composition.

The insulating inner surface of the concrete structure together with the dirt and fill surface therebetween provides a continuous forming surface for a slab form. In many cases, gravel, stone, utility lines, heating lines, expansion joints, or other desirable under concrete material and/or items as are known in the art are placed along the continuous forming surface. A concrete composition is then placed to within the continuous forming surface and allowed to cure and harden to form a concrete slab within the concrete structure.

In embodiments of the invention shown in FIG. 14, insulating pier form 301 is placed at a corner of concrete structure 300 and has rebar 302 and concrete 304 placed in mold chamber 306. Water impervious fabric 307 is placed over the outward facing surface of insulating pier form 301. Outer fill 308 is placed in the excavated space between insulating pier form 301 and undisturbed ground 310 and is in contact with water impervious fabric 307. Inner fill 312 is placed in the excavated space between insulating pier form 300 and undisturbed ground 314. Crushed stone 316 is placed as a surface onto which slab 318 is placed. Slab 318 is reinforced with rebar 320. Load bearing column 322 is placed on top of concrete 304 and attached by way of connectors 324, which can be embedded in, anchored in or otherwise secured to concrete 304.

In other embodiments of the invention shown in FIG. 15, insulating concrete form 352 is placed along an excavated perimeter of concrete structure 350 and has rebar 354 and concrete 356 placed in mold chamber 358. Water impervious fabric 359 is placed over the outward facing surface of insulating concrete form 352. Outer fill 360 is placed in the excavated space between insulating concrete form 352 and undisturbed ground 310 and is in contact with water impervious fabric 359. Inner fill 364 is placed in the excavated space between insulating concrete form 352 and undisturbed ground 366. Crushed stone 368 is placed as a surface onto which slab 370 is placed. Slab 370 is reinforced with rebar 372. Wall 322 is placed on top of concrete 356 and attached by way of base channel 372, which can be embedded in, anchored in or otherwise secured to concrete 356.

In embodiments of the invention as shown in FIG. 16, frost wall 400 includes insulating pier form 402 with concrete 404 and rebar 406 therein, first insulating concrete form 408 and second insulating concrete form 410, the surface of each can optionally be covered by a water impervious fabric. In this embodiment, footer portion 412 of insulating pier form 402 extends further into undisturbed ground 414 than first insulating concrete form 408 and second insulating concrete form 410. A portion of bottom surface 416 of first insulating concrete form 408 rests on top surface 418 of footer portion 412 of insulating pier form 402 and the remainder of bottom surface 416 of first insulating concrete form 408 rests on undisturbed ground 414. Similarly, a portion of bottom surface 420 of second insulating concrete form 410 rests on top surface 422 of footer portion 412 of insulating pier form 402 and the remainder of bottom surface 420 of second insulating concrete form 410 rests on undisturbed ground 414.

In other embodiments of the invention as shown in FIG. 17, frost wall 450 includes insulating pier form 452 with concrete 454 and rebar 456 therein, first insulating concrete form 458 and second insulating concrete form 460 the surface of each can optionally be covered by a water impervious fabric. In this embodiment, footer portion 452 of insulating pier form 462 extends to the same depth of undisturbed ground 454 as first insulating concrete form 458 and second insulating concrete form 460. A portion of bottom surface 466 of first insulating concrete form 458 is cut away to conform to the shape of footer portion 462 of insulating pier form 452 and the remainder of bottom surface 466 of first insulating concrete form 458 is at the same depth as the bottom of insulating pier form 452. Similarly, a portion of bottom surface 468 of second insulating concrete form 460 is cut away to conform to the shape of footer portion 462 of insulating pier form 452 and the remainder of bottom surface 468 of second insulating concrete form 460 is at the same depth as the bottom of insulating pier form 452.

A particular advantage of using the systems, methods and articles for constructing a shallow pier foundation or pier and floating slab building according to the present invention is that it provides improved resistance from frost heave in general and to vertical and lateral movements of the soil, occurring as a result of mud, frost, thawing, etc., in particular. Additionally, the present structures and methods provide improved economy as the construction process can be completed in a shorter period of time. Thus, the present invention provides improved systems, methods and structures allowing more secure support in an arrangement and/or system for pier and floating slab foundations, and which minimize and/or eliminate the deficiencies in the prior art.

The insulating pier forms and insulating concrete forms described herein (“mold units”) are made of a foamed plastic that can be produced by expanding an expandable polymer matrix. The expanded polymer matrix typically includes expandable thermoplastic particles. These expandable thermoplastic particles are made from any suitable thermoplastic homopolymer or copolymer. Particularly suitable for use are homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the like, as well as copolymers prepared by the copolymerization of at least one vinyl aromatic monomer as described above with one or more other monomers, non-limiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer. In an embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers can be used, such as polyolefins (e.g., polyethylene, polypropylene), polycarbonates, polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the expandable thermoplastic particles are expandable polystyrene (EPS) particles. These particles can be in the form of beads, granules, or other particles convenient for the expansion and molding operations. Particles polymerized in an aqueous suspension process are essentially spherical and are useful for molding the mold units and/or forms described herein below. These particles can be screened so that their size ranges from about 0.008 inches (0.2 mm) to about 0.16 inches (4 mm).

In an embodiment of the invention, resin beads (unexpanded) containing any of the polymers or polymer compositions described herein have a particle size of at least 0.2 mm, in some situations at least 0.33 mm, in some cases at least 0.35 mm, in other cases at least 0.4 mm, in some instances at least 0.45 mm and in other instances at least 0.5 mm. Also, the resin beads can have a particle size of up to about 4 mm, in some situations up to about 3.5 mm, in other situations up to about 3 mm, in some instances up to 2 mm, in other instances up to 2.5 mm, in some cases up to 2.25 mm, in other cases up to 2 mm, in some situations up to 1.5 mm and in other situations up to 1 mm. The resin beads used in this embodiment can be any value or can range between any of the values recited above.

The average particle size and size distribution of the expandable resin beads or pre-expanded resin beads can be determined using low angle light scattering, which can provide a weight average value. As a non-limiting example, a Model LA-910 Laser Diffraction Particle Size Analyzer available from Horiba Ltd., Kyoto, Japan can be used

As used herein, the terms “expandable thermoplastic particles” or “expandable resin beads” refers to a polymeric material in particulate or bead form that is impregnated with a blowing agent such that when the particulates and/or beads are placed in a mold or expansion device and heat is applied thereto, evaporation of the blowing agent (as described below) effects the formation of a cellular structure and/or an expanding cellular structure in the particulates and/or beads. When expanded in a mold, the outer surfaces of the particulates and/or beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold.

As used herein, the terms “pre-expanded thermoplastic particles”, “pre-expanded resin beads” or “prepuff” refers to expandable resin beads that have been expanded, but not to their maximum expansion factor and whose outer surfaces have not fused. As used herein, the term “expansion factor” refers to the volume a given weight of resin bead occupies, typically expressed as cc/g. Pre-expanded resin beads can be further expanded in a mold where the outer surfaces of the pre-expanded resin beads fuse together to form a continuous mass of polymeric material conforming to the shape of the mold.

The expandable thermoplastic particles can be impregnated using any conventional method with a suitable blowing agent. As a non-limiting example, the impregnation can be achieved by adding the blowing agent to the aqueous suspension during the polymerization of the polymer, or alternatively by re-suspending the polymer particles in an aqueous medium and then incorporating the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous material or material which will produce gases on heating can be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and the halogenated hydrocarbons, e.g., CFC's and HCFC's, which boil at a temperature below the softening point of the polymer chosen. Mixtures of these aliphatic hydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbons blowing agents or water can be used as the sole blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents, water-retaining agents are used. The weight percentage of water for use as the blowing agent can range from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein by reference.

The impregnated thermoplastic particles are generally pre-expanded to a density of at least 0.5 lb/ft³, in some cases at least 0.75 lb/ft³, in other cases at least 1.0 lb/ft³, in some situations at least 1.25 lb/ft³, in other situations at least 1.5 lb/ft³, and in some instances at least about 1.75 lb/ft³. Also, the density of the impregnated pre-expanded particles can be up to 12 lb/ft³, in some cases up to 10 lb/ft³, and in other cases up to 5 lb/ft³. The density of the impregnated pre-expanded particles can be any value or range between any of the values recited above. The pre-expansion step is conventionally carried out by heating the impregnated beads via any conventional heating medium, such as steam, hot air, hot water, or radiant heat. One generally accepted method for accomplishing the pre-expansion of impregnated thermoplastic particles is taught in U.S. Pat. No. 3,023,175.

The impregnated thermoplastic particles can be foamed cellular polymer particles as taught in U.S. Publication Application No. 2002/0117769, the teachings of which are incorporated herein by reference. The foamed cellular particles can be polystyrene that are pre-expanded and contain a volatile blowing agent at a level of less than 14 wt. %, in some situations less than 8 wt. %, in some cases ranging from about 2 wt. % to about 7 wt. %, and in other cases ranging from about 2.5 wt. % to about 6.5 wt. % based on the weight of the polymer.

The thermoplastic particles according to the invention can include an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers. Non-limiting examples of such interpolymers are disclosed in U.S. Pat. Nos. 4,303,756 and 4,303,757 and U.S. Application Publication 2004/0152795, the relevant portions of which are herein incorporated by reference. A non-limiting example of interpolymers that can be used in the present invention include those available under the trade name ARCEL®, available from NOVA Chemicals Inc., Pittsburgh, Pa. and PIOCELAN®, available from Sekisui Plastics Co., Ltd., Tokyo, Japan.

The expanded polymer matrix can include customary ingredients and additives, such as pigments, dyes, colorants, plasticizers, mold release agents, stabilizers, ultraviolet light absorbers, mold prevention agents, antioxidants, and so on. Typical pigments include, without limitation, inorganic pigments such as carbon black, graphite, expandable graphite, zinc oxide, titanium dioxide, and iron oxide, as well as organic pigments such as quinacridone reds and violets and copper phthalocyanine blues and greens.

In a particular embodiment of the invention, the pigment is carbon black, a non-limiting example of such a material being EPS SILVER®, available from NOVA Chemicals Inc.

In another particular embodiment of the invention, the pigment is graphite, a non-limiting example of such a material being NEOPOR®, available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.

The pre-expanded particles or “pre-puff” are usually heated in a closed mold to form the present mold units.

Any suitable type of concrete composition can be used to make the concrete piers, walls and concrete foundation systems described herein. The specific type of concrete will depend on the desired and designed properties of the concrete piers, walls and foundation systems. In embodiments of the invention, the concrete includes one or more hydraulic cement compositions selected from Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.

In an embodiment of the invention, the cement includes a hydraulic cement composition. The hydraulic cement composition can be present at a level of at least 3, in certain situations at least 5, in some cases at least 7.5, and in other cases at least 9 volume percent and can be present at levels up to 40, in some cases up to 35, in other cases up to 32.5, and in some instances up to 30 volume percent of the cement mixture. The cement mixture can include the hydraulic cement composition at any of the above-stated levels or at levels ranging between any of levels stated above.

In an embodiment of the invention, the concrete mixture can optionally include other aggregates and adjuvants known in the art including but not limited to sand, additional aggregate, plasticizers and/or fibers. Suitable fibers include, but are not limited to glass fibers, silicon carbide, aramid fibers, polyester, carbon fibers, composite fibers, fiberglass, metal and combinations thereof as well as fabric containing the above-mentioned fibers, and fabric containing combinations of the above-mentioned fibers.

Non-limiting examples of fibers that can be used in the invention include MeC-GRID® and C-GRID® available from TechFab, LLC, Anderson, S.C., KEVLAR® available from E.I. du Pont de Nemours and Company, Wilmington, Del., TWARON® available from Teijin Twaron B.V., Arnheim, the Netherlands, SPECTRA® available from Honeywell International Inc., Morristown, N.J., DACRON® available from Invista North America S.A.R.L. Corp. Wilmington, Del., and VECTRAN® available from Hoechst Celanese Corp., New York, N.Y. The fibers can be used in a mesh structure, intertwined, interwoven, and oriented in any desirable direction.

In a particular embodiment of the invention, fibers can make up at least 0.1, in some cases at least 0.5, in other cases at least 1, and in some instances at least 2 volume percent of the concrete composition. Further, fibers can provide up to 10, in some cases up to 8, in other cases up to 7, and in some instances up to 5 volume percent of the concrete composition. The amount of fibers is adjusted to provide desired properties to the concrete composition. The amount of fibers can be any value or range between any of the values recited above.

Further to this embodiment, the additional aggregate can include, but is not limited to, one or more materials selected from common aggregates such as sand, stone, and gravel. Common lightweight aggregates can include ground granulated blast furnace slag, fly ash, glass, silica, expanded slate and clay; insulating aggregates such as pumice, perlite, vermiculite, scoria, and diatomite; light-weight aggregate such as expanded shale, expanded slate, expanded clay, expanded slag, fumed silica, pelletized aggregate, extruded fly ash, tuff, and macrolite; and masonry aggregate such as expanded shale, clay, slate, expanded blast furnace slag, sintered fly ash, coal cinders, pumice, scoria, and pelletized aggregate.

When included, the other aggregates and adjuvants are present in the concrete mixture at a level of at least 0.5, in some cases at least 1, in other cases at least 2.5, in some instances at least 5 and in other instances at least 10 volume percent of the concrete mixture. Also, the other aggregates and adjuvants can be present at a level of up to 95, in some cases up to 90, in other cases up to 85, in some instances up to 65 and in other instances up to 60 volume percent of the concrete mixture. The other aggregates and adjuvants can be present in the concrete mixture at any of the levels indicated above or can range between any of the levels indicated above.

In embodiments of the invention, the concrete compositions can contain one or more additives, non-limiting examples of such being anti-foam agents, water-proofing agents, dispersing agents, set-accelerators, set-retarders, plasticizing agents, superplasticizing agents, freezing point decreasing agents, adhesiveness-improving agents, and colorants. The additives are typically present at less than one percent by weight with respect to total weight of the composition, but can be present at from 0.1 to 3 weight percent.

Suitable dispersing agents or plasticizers that can be used in the invention include, but are not limited to hexametaphosphate, tripolyphosphate, polynaphthalene sulphonate, sulphonated polyamine and combinations thereof.

Suitable plasticizing agents that can be used in the invention include, but are not limited to polyhydroxycarboxylic acids or salts thereof, polycarboxylates or salts thereof; lignosulfonates, polyethylene glycols, and combinations thereof.

Suitable superplasticizing agents that can be used in the invention include, but are not limited to alkaline or earth alkaline metal salts of lignin sulfonates; lignosulfonates, alkaline or earth alkaline metal salts of highly condensed naphthalene sulfonic acid/formaldehyde condensates; polynaphthalene sulfonates, alkaline or earth alkaline metal salts of one or more polycarboxylates (such as poly(meth)acrylates and the polycarboxylate comb copolymers described in U.S. Pat. No. 6,800,129, the relevant portions of which are herein incorporated by reference); alkaline or earth alkaline metal salts of melamine/formaldehyde/sulfite condensates; sulfonic acid esters; carbohydrate esters; and combinations thereof.

Suitable set-accelerators that can be used in the invention include, but are not limited to soluble chloride salts (such as calcium chloride), triethanolamine, paraformaldehyde, soluble formate salts (such as calcium formate), sodium hydroxide, potassium hydroxide, sodium carbonate, sodium sulfate, 12CaO.7Al₂O₃, sodium sulfate, aluminum sulfate, iron sulfate, the alkali metal nitrate/sulfonated aromatic hydrocarbon aliphatic aldehyde condensates disclosed in U.S. Pat. No. 4,026,723, the water soluble surfactant accelerators disclosed in U.S. Pat. No. 4,298,394, the methylol derivatives of amino acids accelerators disclosed in U.S. Pat. No. 5,211,751, and the mixtures of thiocyanic acid salts, alkanolamines, and nitric acid salts disclosed in U.S. Pat. No. Re. 35,194, the relevant portions of which are herein incorporated by reference, and combinations thereof.

Suitable set-retarders that can be used in the invention include, but are not limited to lignosulfonates, hydroxycarboxylic acids (such as gluconic acid, citric acid, tartaric acid, maleic acid, salicylic acid, glucoheptonic acid, arabonic acid, and inorganic or organic salts thereof such as sodium, potassium, calcium, magnesium, ammonium and triethanolamine salt), cardonic acid, sugars, modified sugars, phosphates, borates, silico-fluorides, calcium bromate, calcium sulfate, sodium sulfate, monosaccharides such as glucose, fructose, galactose, saccharose, xylose, apiose, ribose and invert sugar, oligosaccharides such as disaccharides and trisaccharides, such oligosaccharides as dextrin, polysaccharides such as dextran, and other saccharides such as molasses containing these; sugar alcohols such as sorbitol; magnesium silicofluoride; phosphoric acid and salts thereof, or borate esters; aminocarboxylic acids and salts thereof; alkali-soluble proteins; humic acid; tannic acid; phenols; polyhydric alcohols such as glycerol; phosphonic acids and derivatives thereof, such as aminotri(methylenephosphonic acid), 1-hydroxyethylidene-1,1-diphosphonic acid, ethylenediaminetetra(methylene-phosphonic acid), diethylenetriaminepenta(methylenephosphonic acid), and alkali metal or alkaline earth metal salts thereof, and combinations of the set-retarders indicated above.

Suitable defoaming agents that can be used in the invention include, but are not limited to silicone-based defoaming agents (such as dimethylpolysiloxane, dimethylsilicone oil, silicone paste, silicone emulsions, organic group-modified polysiloxanes (polyorganosiloxanes such as dimethylpolysiloxane), fluorosilicone oils, etc.), alkyl phosphates (such as tributyl phosphate, sodium octylphosphate, etc.), mineral oil-based defoaming agents (such as kerosene, liquid paraffin, etc.), fat- or oil-based defoaming agents (such as animal or vegetable oils, sesame oil, castor oil, alkylene oxide adducts derived therefrom, etc.), fatty acid-based defoaming agents (such as oleic acid, stearic acid, and alkylene oxide adducts derived therefrom, etc.), fatty acid ester-based defoaming agents (such as glycerol monoricinolate, alkenylsuccinic acid derivatives, sorbitol monolaurate, sorbitol trioleate, natural waxes, etc.), oxyalkylene type defoaming agents, alcohol-based defoaming agents: octyl alcohol, hexadecyl alcohol, acetylene alcohols, glycols, etc.), amide-based defoaming agents (such as acrylate polyamines, etc.), metal salt-based defoaming agents (such as aluminum stearate, calcium oleate, etc.) and combinations of the above-described defoaming agents.

Suitable freezing point decreasing agents that can be used in the invention include, but are not limited to ethyl alcohol, calcium chloride, potassium chloride, and combinations thereof.

Suitable adhesiveness-improving agents that can be used in the invention include, but are not limited to polyvinyl acetate, styrene-butadiene, homopolymers and copolymers of (meth)acrylate esters, and combinations thereof.

Suitable water-repellent or water-proofing agents that can be used in the invention include, but are not limited to fatty acids (such as stearic acid or oleic acid), lower alkyl fatty acid esters (such as butyl stearate), fatty acid salts (such as calcium or aluminum stearate), silicones, wax emulsions, hydrocarbon resins, bitumen, fats and oils, silicones, paraffins, asphalt, waxes, and combinations thereof. Although not used in many embodiments of the invention, when used, suitable air-entraining agents include, but are not limited to vinsol resins, sodium abietate, fatty acids and salts thereof, tensides, alkyl-aryl-sulfonates, phenol ethoxylates, lignosulfonates, and mixtures thereof.

In some embodiments of the invention, the concrete is light weight concrete. As used herein, the term “light weight concrete” refers to concrete where light-weight aggregate is included in a cementitous mixture. Exemplary light weight concrete compositions that can be used in the present invention are disclosed in U.S. Pat. Nos. 3,021,291, 3,214,393, 3,257,338, 3,272,765, 5,622,556, 5,725,652, 5,580,378, and 6,851,235, U.S. Patent Application Publication No. 2007/0125275 as well as JP 9 071 449, WO 98 02 397, WO 00/61519, and WO 01/66485 the relevant portions of which are incorporated herein by reference.

In particular embodiments of the present invention, the lightweight concrete (LWC) composition includes a concrete mixture and polymer particles. In many instances, the size, composition, structure, and physical properties of expanded polymer particles, and in some instances their resin bead precursors, can greatly affect the physical properties of LWC used in the invention. Of particular note is the relationship between bead size and expanded polymer particle density on the physical properties of the resulting LWC wall.

The polymer particles, which can optionally be expanded polymer particles, are present in the LWC composition at a level of at least 10, in some instances at least 15, in other instances at least 20, in particular situations up to 25, in some cases at least 30, and in other cases at least 35 volume percent and up to 90, in some cases up to 85, in other cases up to 78, in some instances up to 75, in other instance up to 65, in particular instances up to 60, in some cases up to 50, and in other cases up to 40 volume percent based on the total volume of the LWC composition. The amount of polymer particles will vary depending on the particular physical properties desired in a finished LWC wall. The amount of polymer particles in the LWC composition can be any value or can range between any of the values recited above.

The polymer particles can include any particles derived from any suitable expandable thermoplastic material. The actual polymer particles are selected based on the particular physical properties desired in a finished LWC wall. As a non-limiting example, the polymer particles, which can optionally be expanded polymer particles, can include one or more polymers selected from homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; polyesters; polyamides; natural rubbers; synthetic rubbers; and combinations thereof.

In an embodiment of the invention, the polymer particles include thermoplastic homopolymers or copolymers selected from homopolymers derived from vinyl aromatic monomers including styrene, isopropylstyrene, alpha-methylstyrene, nuclear methylstyrenes, chlorostyrene, tert-butylstyrene, and the like, as well as copolymers prepared by the copolymerization of at least one vinyl aromatic monomer as described above with one or more other monomers, non-limiting examples being divinylbenzene, conjugated dienes (non-limiting examples being butadiene, isoprene, 1,3- and 2,4-hexadiene), alkyl methacrylates, alkyl acrylates, acrylonitrile, and maleic anhydride, wherein the vinyl aromatic monomer is present in at least 50% by weight of the copolymer. In an embodiment of the invention, styrenic polymers are used, particularly polystyrene. However, other suitable polymers can be used, such as polyolefins (e.g., polyethylene, polypropylene), polyearbonates, polyphenylene oxides, and mixtures thereof.

In a particular embodiment of the invention, the polymer particles are expandable polystyrene (EPS) particles. These particles can be in the form of beads, granules, or other particles.

In the present invention, particles polymerized in a suspension process, which are essentially spherical resin beads, are useful as polymer particles or for making expanded polymer particles. However, polymers derived from solution and bulk polymerization techniques that are extruded and cut into particle sized resin bead sections can also be used.

In an embodiment of the invention, resin beads (unexpanded) containing any of the polymers or polymer compositions described herein have a particle size of at least 0.2 mm, in some situations at least 0.33 mm, in some cases at least 0.35 mm, in other cases at least 0.4 mm, in some instances at least 0.45 mm and in other instances at least 0.5 mm. Also, the resin beads can have a particle size of up to 3 mm, in some instances up to 2 mm, in other instances up to 2.5 mm, in some cases up to 2.25 mm, in other cases up to 2 mm, in some situations up to 1.5 mm and in other situations up to 1 mm. In this embodiment, the physical properties of LWC walls made according to the invention have inconsistent or undesirable physical properties when resin beads having particle sizes outside of the above described ranges are used to make the expanded polymer particles. The resin beads used in this embodiment can be any value or can range between any of the values recited above.

The expandable thermoplastic particles or resin beads can optionally be impregnated using any conventional method with a suitable blowing agent. As a non-limiting example, the impregnation can be achieved by adding the blowing agent to the aqueous suspension during the polymerization of the polymer, or alternatively by re-suspending the polymer particles in an aqueous medium and then incorporating the blowing agent as taught in U.S. Pat. No. 2,983,692. Any gaseous material or material which will produce gases on heating can be used as the blowing agent. Conventional blowing agents include aliphatic hydrocarbons containing 4 to 6 carbon atoms in the molecule, such as butanes, pentanes, hexanes, and the halogenated hydrocarbons, e.g., CFC's and HCFC's, which boil at a temperature below the softening point of the polymer chosen. Mixtures of these aliphatic hydrocarbon blowing agents can also be used.

Alternatively, water can be blended with these aliphatic hydrocarbons blowing agents or water can be used as the sole blowing agent as taught in U.S. Pat. Nos. 6,127,439; 6,160,027; and 6,242,540 in these patents, water-retaining agents are used. The weight percentage of water for use as the blowing agent can range from 1 to 20%. The texts of U.S. Pat. Nos. 6,127,439, 6,160,027 and 6,242,540 are incorporated herein by reference.

The impregnated polymer particles or resin beads are optionally expanded to a bulk density of at least 1.75 lb/ft³ (0.028 g/cc), in some circumstances at least 2 lb/ft³ (0.032 g/cc) in other circumstances at least 3 lb/ft³ (0.048 g/cc) and in particular circumstances at least 3.25 lb/ft³ (0.052 g/cc) or 3.5 lb/ft³ (0.056 g/cc). When non-expanded resin beads are used, higher bulk density beads can be used. As such, the bulk density can be as high as 40 lb/ft³ (0.64 g/cc). In other situations, the polymer particles are at least partially expanded and the bulk density can be up to 35 lb/ft³ (0.56 g/cc), in some cases up to 30 lb/ft³ (0.48 g/cc), in other cases up to 25 lb/ft³ (0.4 g/cc), in some instances up to 20 lb/ft³ (0.32 g/cc), in other instances up to 15 lb/ft³ (0.24 g/cc) and in certain circumstances up to 10 lb/ft³ (0.16 g/cc). The bulk density of the polymer particles can be any value or range between any of the values recited above. The bulk density of the polymer particles, resin beads and/or prepuff particles is determined by weighing a known volume of polymer particles, beads and/or prepuff particles (aged 24 hours at ambient conditions).

The expansion step is conventionally carried out by heating the impregnated beads via any conventional heating medium, such as steam, hot air, hot water, or radiant heat. One generally accepted method for accomplishing the pre-expansion of impregnated thermoplastic particles is taught in U.S. Pat. No. 3,023,175.

The impregnated polymer particles can be foamed cellular polymer particles as taught in U.S. Publication Application No. 2002/0117769, the teachings of which are incorporated herein by reference. The foamed cellular particles can be polystyrene that are expanded and contain a volatile blowing agent at a level of less than 14 wt. %, in some situations less than 8 wt. %, in some cases ranging from about 2 wt. % to about 7 wt. %, and in other cases ranging from about 2.5 wt. % to about 6.5 wt. % based on the weight of the polymer.

An interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers that can be included in the expanded thermoplastic resin or polymer particles according to the invention is disclosed in U.S. Pat. Nos. 4,303,756 and 4,303,757 and U.S. Application Publication 2004/0152795, the relevant portions of which are herein incorporated by reference.

The polymer particles can include customary ingredients and additives, such as flame retardants, pigments, dyes, colorants, plasticizers, mold release agents, stabilizers, ultraviolet light absorbers, mold prevention agents, antioxidants, rodenticides, insect repellants, and so on. Typical pigments include, without limitation, inorganic pigments such as carbon black, graphite, expandable graphite, zinc oxide, titanium dioxide, and iron oxide, as well as organic pigments such as quinacridone reds and violets and copper phthalocyanine blues and greens.

In a particular embodiment of the invention, the pigment is carbon black, a non-limiting example of such a material being EPS SILVER®, available from NOVA Chemicals Inc.

In another particular embodiment of the invention, the pigment is graphite, a non-limiting example of such a material being NEOPOR®, available from BASF Aktiengesellschaft Corp., Ludwigshafen am Rhein, Germany.

When materials such as carbon black and/or graphite are included in the polymer particles, improved insulating properties, as exemplified by higher R values for materials containing carbon black or graphite (as determined using ASTM-C518), are provided. As such, the R value of the expanded polymer particles containing carbon black and/or graphite or materials made from such polymer particles are at least 5% higher than observed for particles or resulting walls that do not contain carbon black and/or graphite.

The expanded polymers can have an average particle size of at least 0.2, in some circumstances at least 0.3, in other circumstances at least 0.5, in some cases at least 0.75, in other cases at least 0.9 and in some instances at least 1 mm and can be up to 8, in some circumstances up to 6, in other circumstances up to 5, in some cases up to 4, in other cases up to 3, and in some instances up to 2.5 mm. When the size of the expanded polymer particles is too small or too large, the physical properties of LWC walls made using the present LWC composition can be undesirable. The average particle size of the expanded polymer particles can be any value and can range between any of the values recited above. The average particle size of the expanded polymer particles can be determined using laser diffraction techniques or by screening according to mesh size using mechanical separation methods well known in the art.

In an embodiment of the invention, the polymer particles or expanded polymer particles have a minimum average cell wall thickness, which helps to provide desirable physical properties to LWC walls made using the present LWC composition. The average cell wall thickness and inner cellular dimensions can be determined using scanning electron microscopy techniques known in the art. The expanded polymer particles can have an average cell wall thickness of at least 0.15 μm, in some cases at least 0.2 μm and in other cases at least 0.25 μm. Not wishing to be bound to any particular theory, it is believed that a desirable average cell wall thickness results when resin beads having the above-described dimensions are expanded to the above-described densities.

In an embodiment of the invention, the polymer beads are optionally expanded to form the expanded polymer particles such that a desirable cell wall thickness as described above is achieved. Though many variables can impact the wall thickness, it is desirable, in this embodiment, to limit the expansion of the polymer bead so as to achieve a desired wall thickness and resulting expanded polymer particle strength. Optimizing processing steps and blowing agents can expand the polymer beads to a minimum of 1.75 lb/ft³ (0.028 g/cc). This property of the expanded polymer bulk density, can be described by pcf (lb/ft³) or by an expansion factor (cc/g).

As used herein, the term “expansion factor” refers to the volume a given weight of expanded polymer bead occupies, typically expressed as cc/g.

In order to provide expanded polymer particles with desirable cell wall thickness and strength, the expanded polymer particles are not expanded to their maximum expansion factor; as such, an extreme expansion yields particles with undesirably thin cell walls and insufficient strength. Further, the polymer beads can be expanded at least 5%, in some cases at least 10%, and in other cases at least 15% of their maximum expansion factor. However, so as not to cause the cell wall thickness to be too thin, the polymer beads are expanded up to 80%, in some cases up to 75%, in other cases up to 70%, in some instances up to 65%, in other instances up to 60%, in some circumstances up to 55%, and in other circumstances up to 50% of their maximum expansion factor. The polymer beads can be expanded to any degree indicated above or the expansion can range between any of the values recited above. Typically, the polymer beads or prepuff beads do not further expand when formulated into the present concrete compositions and do not further expand while the concrete compositions set, cure and/or harden.

The prepuff or expanded polymer particles typically have a cellular structure or honeycomb interior portion and a generally smooth continuous polymeric surface as an outer surface, i.e., a substantially continuous outer layer. The smooth continuous surface can be observed using scanning electron microscope (SEM) techniques at 1000× magnification. SEM observations do not indicate the presence of holes in the outer surface of the prepuff or expanded polymer particles. Cutting sections of the prepuff or expanded polymer particles and taking SEM observations reveals the generally honeycomb structure of the interior of the prepuff or expanded polymer particles.

The polymer particles or expanded polymer particles can have any cross-sectional shape that allows for providing desirable physical properties in LWC walls. In an embodiment of the invention, the expanded polymer particles have a circular, oval or elliptical cross-section shape. In embodiments of the invention, the prepuff or expanded polymer particles have an aspect ratio of 1, in some cases at least 1 and the aspect ratio can be up to 3, in some cases up to 2 and in other cases up to 1.5. The aspect ratio of the prepuff or expanded polymer particles can be any value or range between any of the values recited above.

In particular embodiments of the invention, the light weight concrete includes from 10 to 90 volume percent of a cement composition, from 10 to 90 volume percent of particles having an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.028 g/cc to 0.64 g/cc, an aspect ratio of from 1 to 3, and from 10 to 50 volume percent of sand and/or other fine aggregate, where the sum of components used does not exceed 100 volume percent.

Light weight concrete compositions that are particularly useful in the present invention include those disclosed in co-pending U.S. Publication Application No. 2002/0117769, the relevant portions of the disclosure are incorporated herein by reference.

The present invention has been described with reference to specific details of particular embodiments thereof. It is not intended that such details be regarded as limitations upon the scope of the invention except insofar as and to the extent that they are included in the accompanying claims. 

1. A method of constructing a shallow pier foundation building comprising: a) placing a plurality of insulating pier forms along a perimeter of the building; b) placing a plurality of insulating concrete forms between the insulating piers to form a continuous insulating surface to the surrounding soil and a continuous forming surface to provide a slab form; c) placing a concrete composition in the insulating piers and insulating concrete forms and allowing the concrete composition to cure and harden; and d) placing a concrete slab composition in the slab form and allowing the concrete composition to cure and harden.
 2. The method according to claim 1, wherein the insulating pier form comprises (A) a first panel member comprising a first end and a second end: (B) a second panel member comprising a first end and a second end, wherein the first end is connected to the second end of the first panel; (C) a third panel member comprising a first end and a second end, wherein the first end is connected to the second end of the second panel; and (D) a fourth panel member comprising a first end and a second end, wherein the first end is connected to the second end of the third panel and the second end is connected to the first end of the first panel; wherein the first, second, third and forth panels maintain a spatial distance therebetween for defining a molding chamber generally having a rectangular cross section.
 3. The method according to claim 1, wherein the insulating concrete form comprises (A) a first panel member comprising: (1) a first outer panel side including a first wall surface area extending generally vertically thereon; (2) a first inner panel side positioned oppositely from said first outer panel side; and (3) at least two first slots in the first inner panel side adapted to accept a connecting member; (B) a second panel member comprising: (1) a second outer panel side including a second wall surface area extending generally vertically thereon and facing oppositely from said first panel member; (2) a second inner panel side positioned oppositely from said second outer panel side and facing said first inner panel side of said first panel member; and (3) at least two second slots in the second inner panel side adapted to accept a connecting member; and (C) at least two connecting members detachable and securable with respect to said first panel member and said second panel member adapted to maintain a spatial distance therebetween for defining a molding chamber therebetween, the connecting members comprising: (1) a first flange detachably and securably extending within said first slot of said first panel member; (2) a second flange detachably and securably extending within said second slot of said second panel member; and (3) a mid-section portion.
 4. The method according to claim 1, wherein the insulating pier form and the insulating concrete form comprise an expanded polymer matrix.
 5. The method according to claim 4, wherein the expanded polymer matrix comprises one or more polymers selected from the group consisting of homopolymers of vinyl aromatic monomers; copolymers of at least one vinyl aromatic monomer with one or more of divinylbenzene, conjugated dienes, alkyl methacrylates, alkyl acrylates, acrylonitrile, and/or maleic anhydride; polyolefins; polycarbonates; an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and combinations thereof.
 6. The method according to claim 4, wherein the polymer matrix comprises carbon black, graphite or a combination thereof.
 7. The method according to claim 3, wherein the first panel member and the second panel member each have a male end comprising a tongue edge and a female end comprising a female groove edge that facilitates a tongue and groove union between corresponding members.
 8. The method according to claim 3, wherein the connecting member comprises a material selected from the group consisting of plastics, metal, construction grade plastics, composite materials, ceramics, and the like.
 9. The method according to claim 1, wherein the concrete comprises one or more cements selected from the group consisting of Portland cements, pozzolana cements, gypsum cements, aluminous cements, magnesia cements, silica cements, and slag cements.
 10. The method according to claim 1, wherein the concrete is light weight concrete.
 11. The method according to claim 9, wherein the concrete comprises 8-20 volume percent cement, 11-50 volume percent sand, 10-31 volume percent expanded thermoplastic particles, 9-40 volume percent coarse aggregate, and 10-22 volume percent water; wherein the expanded thermoplastic particles have an average particle diameter of from 0.2 mm to 8 mm, a bulk density of from 0.02 g/cc to 0.64 g/cc, an aspect ratio of from 1 to
 3. 12. The method according to claim 2, wherein rebar is placed in the molding chamber prior to placing the concrete.
 13. The method according to claim 3, wherein rebar is placed in the molding chamber prior to placing the concrete.
 14. The method according to claim 11, wherein the expanded thermoplastic particles comprise polymers containing polymerized residues from one or more monomers selected from the group consisting of styrene, ethylene, propylene, and methyl(meth)acrylate; an interpolymer of a polyolefin and in situ polymerized vinyl aromatic monomers; and combinations thereof.
 15. The method according to claim 1, wherein a water impervious fabric is placed over the outward facing continuous insulating surface.
 16. The method according to claim 15, wherein a top edge of the water impervious fabric is above grade.
 17. A building constructed according to the method of claim
 1. 